Improved system, method and apparatus for airship manufacture using robotics

ABSTRACT

A system, method and apparatus are proposed to assist in assembling the frame, attaching the skin, and performing other tasks in manufacturing an airship and constructing other structures that are otherwise challenging, inefficient, or unsuitable for humans to perform, and/or that traditionally require significant investments in capital intensive manufacturing facilities. Several embodiments are proposed in which these and other recurring manufacturing tasks can be performed safely and efficiently with the assistance of autonomous, semi-autonomous, and/or human-directed robots, acting independently and in robot swarms.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority under 35 U.S.C. § 119(e)to U.S. Provisional Application No. 63/280,368, filed on Nov. 17, 2021,entitled, “SYSTEM, METHOD AND APPARATUS FOR AIRSHIP MANUFACTURE USINGROBOTICS”. The entire contents of this patent application are herebyincorporated by reference herein.

BACKGROUND Technical Field of the Subject Technology

The subject technology relates to the construction of lighter-than-airairships and other large aviation and aerospace structures that aretall, long, wide, and/or extremely heavy, and which therefore tend torender construction using traditional systems and methods challenging,inefficient, or generally unsuitable for humans to perform, and/or thatotherwise require significant investments to be made in verycapital-intensive manufacturing facilities and equipment.

DESCRIPTION OF THE PRIOR ART

Airships are well known in the art. A rigid or semi-rigid airship ordirigible is a steerable airship with a structural framework thatmaintains the shape of the airship and carries its structural loads, andwith the lift provided by inflating one or multiple interior bags orcompartments with a lighter-than-air gas such as hydrogen or helium. Toobtain sufficient benefit from such lift to carry commercial payloads,airships are traditionally very large. For example, the Graf Zeppelin,which operated commercially from 1928 to 1937, was 776 feet long and hada diameter of over 100 feet. To be capable of carrying meaningfulpayloads, future commercial airships are likely to also be quite large,resulting in significant manufacturing challenges using traditionalmethods.

Historically, airships have been constructed around a keel, althoughApplicant's prior patent applications including Ser. No. 13/855,923,filed on Apr. 3, 2013, now U.S. Pat. No. 9,102,391 (the '391 patent),and Ser. No. 17/005,628, filed on Aug. 28, 2020, now U.S. Pat. No.11,066,145 (the '145 patent), disclose an exoskeleton comprised of aseries of triangular structures formed from hubs and spokes. Therelevant content from such earlier '391 and '145 patents areincorporated in their entirety herein by this reference.

As indicated in the '145 patent, Applicant contemplates that acommercial-sized airship may be approximately 1000 feet in length and200 feet in diameter. In such case, just the airship's exoskeleton andskin surface material will weigh over 250,000 pounds. Such structuralsystems and skin require extensive assembly and lay-up, which if pursuedusing traditional means, would create high demands for capital toconstruct specialized manufacturing facilities and equipment, createchallenges, inefficiencies and safety risks for workers, and result insignificant limitations to rapidly expanding, replicating, or scaling upsuch facilities to manufacture many such airships.

Although for illustrative purposes, this application focuses on adirigible, and in particular an airship such as disclosed in the '145patent, the principles it discloses are relevant to other airships andlarge aviation and aerospace structures including, without limitation,the fuselage of commercial fixed-wing aircraft and the body ofcommercial rockets that encounter similar issues during construction dueto their height, length, diameter, and mass. For example, SpaceX'sFalcon Heavy rocket is 230 feet tall, 40 feet in diameter, andreportedly weighs over 60,000 pounds without fuel. Even larger rocketsare likely to be required in the future for interplanetary missions, themanufacturing challenges of which will inevitably become more difficultusing traditional methods.

Traditionally in the aviation, aerospace and other industries involvingconstruction of very large structures, manufacturing facilities employoverhead cranes, elevated work platforms, complex assembly lines, andrequire specialized equipment to lift, move, and work on such structuresduring construction. This in turn results in highly specialized andcapital-intensive infrastructure, safety concerns, and time-consuming,costly, and difficult manufacturing processes.

U.S. Pat. No. 4,259,776, entitled “Method of Assembly of Airship Hull,”which was filed on Aug. 9, 1978; issued to Airships International, Inc.on Apr. 7, 1981; and that expired on or about Aug. 9, 1998 (the '776patent), contains a description of the various methods that have beenused in the past to assemble or erect large rigid airships, whichdescription is included herein by this reference. As summarized in thebackground provided to patent application Ser. No. 16/156,913, filed onOct. 10, 2018, now U.S. Pat. No. 10,988,226 (the '226 patent), issued toSergey Brin, Alan Weston, et. al. and assigned to LTA Research andExploration LLC, traditionally airships are kept stationary while beingbuilt, which meant that builders must climb to great heights or besuspended at great heights to build airships.

To overcome this limitation, the '776 and '226 patents each disclose amethod of rotating the airship structure, so the work area has thehighest degree of accessibility, convenience, and safety for thepersonnel involved in the assembly, while at the same time retaining theprecise alignment of the components of the hull being assembled. The'776 patent discloses assembly of the principal transverse frames of thehull in the horizontal position, and on completion, raising and placingthe two frames in a “vertical orientation on an endless belt of aircushions supported on a rotating cradle.” One or more such rotatingcradles are then used during installation to rotate the frames andtemporary structure assembly to convenient positions with the aircushions being monitored for pressure, with adjustments being made toprovide adequate support.

The '226 patent discloses use of a “rollercoaster jig” structure toallow an airship (or partially completed portions of it) to be rotatedby adding detachable wheels or rollers to the outer surface of acircular mainframe structure, such wheels being designed “to interfacethe mainframe with the Rollercoaster's rails and allow the mainframe torotate along its axis” while the airship is built so that builders “maystay grounded,” thereby improving safety and enabling greater assemblyspeed. The system, method and apparatuses disclosed in the '226 patentare complemented within U.S. Pat. No. 11,254,408 to Jesus Zatarain, et.al, also assigned to LTA Research (the '408 patent). The '408 patentdescribes use of a “universal jig” to construct the large circularmainframes of the airship hull while each frame is oriented in ahorizontal position; and then once adequately completed structurally,the partially assembled mainframe is erected and placed onto therollercoaster jig disclosed in LTA's '226 patent.

A third patent disclosure, Chinese patent application number CN111232237A, entitled “Framework of large hard airship and method formounting parts outside air bag of large hard airship,” filed by BeijingKongtiangao Technology Co Ltd on Mar. 4, 2020 (the '237 patentapplication), also contemplates rotating the airship to position thework area to be on the portion of the hull nearest to the factory floor.In the '237 patent application, the airship is lifted by a “process aircolumn below the airship,” and then uses manpower or a stepping motorconnected to “rotating slings at the two sides of the airship” to rollthe airship with the aim of conveniently installing the structure andequipment parts of the airship at the lower position, to therebyincrease safety, reduce cost, and avoid the need for expensive liftingplatforms and complex scaffolding.

Heretofore, airship construction has not involved extensive use ofrobotics. LTA's '408 patent mentions robots only twice, and then simplyas a possible alternative operator to assist in assembling the mainframewhile the circular mainframes rest on its universal jig device. Moregenerally, however, as described in an April 2021 article by CMTC(California Manufacturing Technology Consulting) entitled “Ready or Not,Robotics in Manufacturing is on the Rise,” as industrial robots becomefaster, smarter, and cheaper, more and more companies are beginning tointegrate them into their workflow in conjunction with their workforce.Dating back to the early-1990's, NASA, JPL, and various research groupsincluding MIT and the California Institute of Technology haveexperimented with the use of robots for assembling large trussstructures in outer space for the International Space Station, extremelylarge telescopes, and other remotely constructed structures and spacehabitats.

As summarized in the 2002 article by William Doggett, entitled “RoboticAssembly of Truss Structures for Space Systems and Future ResearchPlans,” NASA's Automated Structural Assembly Laboratory (ASAL)demonstrated reliable autonomous assembly and disassembly of an 8-meterplanar structure composed of 102 truss elements covered by 12 panels.The Doggett paper summarizes associated literature regarding fullyautonomous and telerobotic systems for in-space assembly operations,inspection, and maintenance. The Doggett paper, which is incorporatedherein by this reference, summarizes the critical hardware, software,and design philosophy that form the foundation for reliable assemblysystems for such planar structures.

On-orbit fabrication and integration of spacecraft components was alsoinvestigated by Tethers Unlimited, a contractor to NASA's InnovativeAdvanced Concepts (NIAC) program. It this work, Tethers demonstrated thefeasibility of extruding and assembling composite truss-based structuresand enabling robotic systems to perform assembly of these structures ina highly automated manner. In proof-of-concept demonstrations of its socalled SpiderFab robots, NIAC tested custom robot end-effectors andtruss joints; verified the ability of the autonomous robots to grasp,manipulate, and join trusses; and employed a robotic vision system toenable closed-loop control of the assembly to support these functions.Tethers' 2016 final report regarding this work, entitled “SpiderFab:Process for On-Orbit Construction of Kilometer Scale Apertures,” is alsoincorporated herein by reference.

The CMTC article lists six major types of robotics: articulated,Cartesian, cylindrical, spherical, Selective Compliance Assembly RobotArm (SCARA), and delta robots. The article also describes the attributesand types of work for which these types of industrial robotics arerespectively best suited. In addition, the CMTC article describes theapplications for which robots are typically used in manufacturing. Theseapplications include welding, painting, pick & place, packaging &labeling, assembly & disassembly, product inspection, product testing,palletizing, polishing, grinding, and buffing. Other articles summarizethese and other tasks as falling within five general categories:materials handling, welding, assembly, dispensing, and processing. Giventhe advancements in robotic automation, the CMTC article also lists theindustries utilizing automation for greater efficiency, productivity,and precision. According to CMTC, these include electronicsmanufacturing, auto manufacturing, medical, food manufacturing andagriculture.

Although robots are most often associated with the foregoing industriesand working with tiny components, they play an important role inaerospace applications. According to RobotWorx, due to theirreliability, capability and precision, robots are used extensively forthe construction of aircraft engines as well as in performing tasks suchas drilling and painting airframes. According to their article “Robotsin the Aerospace Industry,” the task for which robots are mostfrequently used in aerospace is drilling holes into components. Paintingand inspecting airframes for cracks, de-lamination of composites, andensuring rivets are intact are also common tasks; and ultrasonic imagingis another common task for robots in aerospace.

According to the RobotWorx article, robots can also be used to laycarbon fiber strips in connection with automated fiber placement oncomposite fuselages, which helps to eliminate errors due to the robots'greater precision for cutting and placing fiber. As the articleindicates, it is generally hoped that the utilization of AI (artificialintelligence) and machine learning in the manufacturing process ofaircraft will help to increase the production rate without compromisingthe quality of the product. Aerospace giants, like Boeing and Airbus,are investing in this technology, and along with the previouslyreferenced research into the use of autonomous robots to construct largestructures in outer space, such investments by OEMs are expected to helpthe market for robotics grow in the future.

There has been considerably less use (or proposed use) of robotics withrespect to airship construction. In connection with its hybrid airshipprogram, Lockheed Martin developed U.S. Pat. No. 8,800,628, entitled“Self-propelled airship hull repair system” (the '628 patent) coveringits so-called ‘Self-Propelled Instruments for Damage Evaluation andRepair,’ or SPIDER robot. This robot was programmed to autonomouslyinspect the airship's skin for holes and to repair them when found. TheSPIDER is built with two halves: one half that goes on the exterior ofthe envelope, and the other on the interior. Magnetically coupled, therobot moves across the entire surface of the envelope, with the outerhalf shining a light on the airship's surface while the inner halfdetects potential pinholes using light sensors in the otherwise darkenvelope. When SPIDER detects a hole, it can repair it using a patchingmechanism, and it then sends before and after photos of the area forrepair verification. The robot is designed to operate over anon-uniformly curved surface while also propelling itself up, down, andupside-down in parallel with the airship's final assembly and duringmajor maintenance checks, using optical encoders to measure itsmovement.

A separate Lockheed Martin patent application that subsequently maturedinto U.S. Pat. No. 10,518,861, entitled “Continuous fiber reinforcementfor airship construction” (the '861 patent), discloses use of a similarrobot to the SPIDER disclosed in the '628 patent. In the case of the'861 patent, this robot is proposed as a means for applying continuousfiber reinforcement to a gas-filled shape and thereby eliminating theneed for individual structural joints in hull assembly with use ofcontinuous fiber reinforcement across the three-dimensional surface ofthe airship or aero-stat hull. In accordance with the '861 patentdisclosure, in certain embodiments, a membrane of thin film or fabric,built in the desired hull shape, is first filled with gas and suspendedabove the manufacturing facility floor so that reinforcement fibers canbe applied to its outer surface using a fiber dispenser robot. Asdisclosed, this robot may include a power source, a drive sub-system, apositioning sub-system, a damage reporting sub-system and/or a controlsub-system; and moves along the surface of the gas filled shape “usingwheels, rollers, tracks, balls, or any other types of mechanism thatpermits motion across the membrane.”

As indicated above, in the previously referenced '408 patent, inconjunction with its disclosure of the universal jig, LTA references theuse of robots only twice. Thus, its universal jig is described ascomprising multiple tracks configured in a radial pattern and cartsconfigured to be positionally adjusted along such tracks to assist inconstructing a mainframe of an airship structure. As disclosed therein,each track has a front cart and a back cart on it, whose respectivepurpose is to secure inner and outer portions of the mainframe duringassembly. The specification discloses that these carts may be “utilizedto assist with holding various components of mainframes (e.g., jointsand connectors), allowing human, robotic, or other assembly operators toassemble a mainframe.” The only other reference to robotic assembly inthe over 70-page specification is the explanation that “once the firstcomponent of the mainframe is secured to a cart [ . . . ] an assemblyworker (e.g., a human, mechanical, or robotic assembly worker) may thenattach connectors [and] additional joints may then be attached to theconnectors . . . . This process of connecting joints and connectors maybe repeated until the entire circular mainframe is assembled.”

In U.S. Pat. No. 11,353,856, entitled “System and method for flexiblemanufacturing” (the '856 patent), applicant Arrival Robotics Limited(“Arrival”) discloses a process for creating robotic control formanufacturing products. Arrival is reportedly applying the teachings ofthe '856 patent and related knowhow to employ a microfactory productionmodel to produce commercial electric vehicle vans and buses. Accordingto its materials, “the foundational principle behind microfactories isthe use of technology cells,” which in turn permit a more flexibleassembly method where each technology cell is optimized to performspecific production processes. Arrival estimates that at comparableannual production volumes, the capital investment for its microfactorieswill be 50% less than a traditional OEM production facility, and itsoperational expense saving associated with its microfactories will beapproximately 50% when compared to a traditional OEM facility with asimilar production capacity.

A useful summary of behavior-based robotics, system controls, anddecentralized local control, and hybrid robotic architectures, isprovided in U.S. Pat. No. 7,343,222, entitled “System, method andapparatus for organizing groups of self-configurable mobile roboticagents in a multi-robotic system” (the '222 patent). The use of suchapproaches to enable groups of robots, sometimes referred to as robotswarms for reasons described in the '222 patent, to work together and tospeed up the process of producing large-scale systems is also describedin non-patent literature such as a February 2020 article entitled“Robots assemble large structures from little pieces” written by MITresearchers and published in Motion Design Magazine.

A great need exists for an improved manufacturing system, method andapparatus that will simplify the production of airships and other verylarge and/or very heavy structures, taking full advantage of suchrobotic technologies and control methods, to reduce manufacturing time,cost, and capital investment requirements, while simultaneouslyincreasing the speed of moving from product design to actualmanufacturing, increasing the levels of precision, and making it mucheasier to scale-up production from the first commercial airship toenabling production of multiple units and replication of such productionfacilities in multiple locations.

Summary of Subject Technology & Particular Embodiments

In at least one aspect, the subject technology relates to usingspecially designed and programmed robots to provide fast andcost-effective ways to construct airships and other large structureswith a much lower initial capital investment in facilities and equipmentthan traditional approaches. The disclosure has utility for assemblingthe structure and attaching the exterior skin of an airship and will bedescribed in connection with such utility, although other commercialutilities are contemplated without departing from the principles of thesubject disclosure.

In some embodiments, a group of robots works at heights of 50 feet orgreater, thereby enabling workers to avoid dangerous conditions whenperforming assembly operations, and through innovative sensory systemspermitting automated quality oversight and human supervision from a saferemote location. This combination of experienced technicians overseeingthe robotic capabilities of the system and method will yield superiorresults in a fraction of the time, and at a fraction of the cost oftraditional construction, while dramatically reducing the requiredinfrastructure needed for manufacturing operations.

In another embodiment, a special class of heavy lift robots may be usedin conjunction with other specialized robot worker classes to permit theairship to be produced from the top down, with the active assembly worksurface remaining within a comfortable distance of the manufacturingfacility floor. In such an embodiment, as upper sections of the airshipare completed, the partially completed hull is pushed upward, making itpossible to assemble more of its structure below the completed top,whereupon the process is repeated until the full airship has beenassembled. In an illustrative embodiment of this approach, the outsidesurface material for the airship is attached to the structure as eachsuccessive portion of the hull is assembled rather than after the fullhull is complete. And in yet an additional illustrative embodiment,other subsystems inside the airship and extending from the outsidesurface are also added as the working surface of the partially completedhull are added, rather than waiting to add such components until afterthe entire hull has been physically completed.

In another illustrative embodiment, each robot is controlled bypre-programmed routines and/or through use of sophisticated artificialintelligence (AI) that may be trained to respond to different structuralshapes, systems, parts numbering, and markings, including various formsof visual fiducial markers such as AprilTags. By way of example but notlimitation, where the airship employs a structure such as theexoskeleton in Applicant's '391 patent and '628 patent application, therobots may be pre-programmed to climb existing structure orientthemselves automatically within three-dimensional space so that eachstructural member will be properly aligned when the structure assemblyis completed.

In a further illustrative embodiment, robots utilize remote cameras,computer vision and machine learning to adapt to the geometry of theairship exoskeleton, select and assemble specific parts so that suchrobots assemble the exoskeleton, attach the exterior skin, and performother specialized tasks needed to construct the airship or otherstructure. In addition to labor savings and safety benefits, the use ofsuch robotic technology cells will liberate airship manufacturers fromneeding to install costly overhead cranes and purchasing or installingadditional equipment that would otherwise be required for mass producingairships.

While traditional production assembly solutions (including the use ofoverhead cranes, assembly equipment, elevated worker platforms, and the“rollercoaster jig” proposed in the '226 patent) involve the use ofcapital-intensive manufacturing facilities, specialized equipment andpersonnel, the use of robotic assembly will dramatically speed upbuilding an airship, with each group of robots able to be controlled byan operator standing safely on the ground.

The system and method are also designed with scalability in mind.Because multiple robot classes can be built to work in parallel both incoordinated fashion and on separate tasks or geographic areas, thesystem is able to be readily scaled on multiple levels to meet thedesired project duration regardless of the size of the airship, thenumber of airships, and the number of assembly locations. The ability toenter multiple markets rapidly, create good paying jobs and add to localtax revenue, will assist in building broad community support andadoption.

In one illustrative embodiment, the system builds the airship structurein a linear fashion, with each robot attaching itself to, and derivingsupport from, one or multiple rows of hubs and tubes that have alreadybeen assembled. In an optional embodiment, one or multiple temporaryguide rails that are attached to such pre-assembled components and/orconnected to supports that are separate from the airship's own structureprovide additional support and/or guidance for the robots. And inanother optional embodiment, the system and method employs one ormultiple tracks or floor-mounted rails to provide additional supportand/or guidance for the robots.

The system and method preferably include a locomotion mechanism formoving along such supporting structure, guide rail(s), and/or track(s).In an optional embodiment, including without limitation when the robotcannot be attached to previously completed portions of the structure, aguide rail or track, movement may be achieved through self-locomotion orautonomous motion bases using battery or hydrogen fuel cell electricpower, and/or by being pulled along the guide rail(s) or tracks(s),utilizing wheels, cable crawlers, vacuum suckers, and rack and pinonsystems. When elevated off the manufacturing floor, the system andmethod may optionally include a gantry to hold the robot from a wirecable to protect it against falling. And when operating from the factoryfloor, the system and method may optionally include linear bearings andrecirculating profile rails to enhance load capabilities.

In one illustrative embodiment, the robots are programmed to recognizeshapes, respond to visual fiducial markers, and to perceive obstaclesthrough sensors, and to carry out recurring actions based on such sensordata.

In some embodiments, the robots may be programmed to operateindependently based on machine vision, or pre-programmed to work as aswarm, wherein a group of two or more robots work in concert with oneanother, coordinate motions, destinations, and/or actions, to carry-outpredetermined tasks. In one preferred embodiment, such autonomous robotsare programmed to avoid colliding with other robots, humans and objectsbased on local processor functions.

In one embodiment, portions of the exoskeleton and sub-assemblies may beconstructed in separate processes, that are subsequently combined withother sub-assemblies and partially completed portions of hull. In onesuch embodiment, portions of the exoskeleton may be assembled whilelaying on its side until the full circumference is completed, whereuponthe section is then raised to an upright position so that it can beconnected to other partially completed sections to create a stable basefor attaching guide rails and cables. In another embodiment, speciallydesigned robots are used to hold partially completed circular trusssections in a proper vertical orientation while additional modules areadded and until the full circumference is completed.

In another embodiment, one or more inflatable shapes may be used, aroundwhich the exoskeleton may be constructed by the robots to minimize theneed for overhead cranes or intermediate crosswalks to hold thepartially built exoskeleton until the full circumference can becompleted, thereby enabling the circular shape to distribute the weightof the airship along the full circumference. In another embodiment, suchinflatable structures may be used to hold up the partially completedexoskeleton, thereby reducing some portion of the weight that robotsholding such structure in place must lift.

In yet another embodiment, to minimize the need for cranes, mechanicaland/or hydraulic jacks, and other lifting equipment, the buoyancy ofsuch one or more inflatable shapes may be adjusted to maintain a neutralor desired level of negative buoyancy of the airship or selected portionthereof and so that the weight of such airship or portion thereof alwaysremains in a predetermined acceptable range as construction proceeds.

In certain embodiments such one or more inflatable shapes may be filledwith air; in other embodiments such shape(s) may be filled with alighter-than-air gas such as helium or hydrogen; and in yet anotherembodiment, each of such one or more inflatable shapes may consist ofinflatable layers, an outside layer being filled with lifting gas and aninside layer (also referred to as a “ballonet”) being filled with air.In another embodiment, this order is reversed, with the outside layerbeing filled with air and an inside layer being filled with the liftinggas.

In certain embodiments, an automated control system may be programmed tocontrol the relative quantities of lifting gas and air that is containedin the one or more inflatable shapes, the objective of such controlsystem programming being to continuously monitor the net weight and tomaintain the desired buoyancy characteristics of the airship or airshipparts by adjusting the quantities of air and lifting gas as constructionprogresses so as to maintain both the integrity of said one or moreinflatable shapes as well as the overall neutral or desired net negativebuoyancy level at all times.

In one illustrative embodiment, the net weight of the airship is nevermore than about 25,000 pounds, notwithstanding that the combined weightof the exoskeleton and skin will eventually reach in exceed 250,000pounds.

In certain embodiments an outer layer of lightweight fabric such asaramid fiber or Kevlar® is produced in the desired form of the one ormore inflated shapes, and placed around the outside surface of such oneor more inflatable shapes to reduce the risk of abrasion should theycome into contact with the exoskeleton and/or the risk of being damagedduring construction; and in one preferred embodiment such one or moreinflatable shapes, and this fabric will remain permanently inside theexoskeleton for the lifetime of the airship and serve as the lifting gascompartments and corresponding ballonets, if any, following completionof construction.

In certain embodiments, sleeves are designed in the lightweight fabricdraped over the one or more inflatable shapes through which spokes canbe threaded during assembly of the exoskeleton to thereby assure thatsaid shapes adhere to the desired portion of the exoskeleton.

And in some illustrative embodiments, the placement of hubs, spokes andother key components may be drawn directly using human and/ormachine-readable text or symbols onto the surface of the one or moreinflatable shapes, the lightweight fabric placed around their outsidesurface, if any, and/or on the surface of other components, to assist inlocating such components in three-dimensional space geometry.

In some embodiments, individual robots or robot swarms may utilize suchdrawings, visual fiducial markers, and optional unique numbers to ensurethat the right component part is assembled in the correct position andwith the correct 3-dimensional orientation for the finished exoskeletonand skin placement to be in accordance with the intended designtherefor.

In some embodiments, additive construction technology, 3D printing,stereolithography processes, and the like may be used to provideportions of the exoskeleton and/or skin. In such embodiments, one ormultiple robots may be used to “print” these components. Optionally, insuch cases, a second robot or robot swarm later smooths the surface ofthe object or surface.

In some embodiments, once the exoskeleton is completed, an endcap may becoupled with the exoskeleton and the axle of a turning device may beattached thereto. Once attached, in one preferred embodiment, the amountof lifting gas may then be adjusted to reduce the net weight of theairship body, whereupon in one embodiment the body may be turned by saidaxle to assist in inspections, applying a smooth skin surface, and otherdesired production steps.

And in some embodiments, selected ones of the inflatable shapes may usedto cause the front of the airship to be lowered and the rear of theairship to be elevated to assist in coupling the endcap or the frontcompartment; and selected ones of the inflatable shapes may be used tocause the rear of the airship to be lowered and the front elevated toassist in coupling the endcap or the aft engine.

In one illustrative embodiment multiple robots—homogeneous orheterogeneous—are interconnected, forming a swarm of robots. Sinceindividual robots have processing, communication, and sensingcapabilities locally on-board, they are able to interact with each otherand react to the environment autonomously.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 , including sub-parts 1(a) through 1(c), depicts in subpart 1(a)the exoskeleton structure for a lighter-than-air airship to beconstructed by application of the principles of this disclosure.

FIG. 1(b) illustrates a standard truss module that when connected withadjacent truss modules may be used to construct circular structuralframes as part of such exoskeleton structure.

FIG. 1(c) provides a schematic illustration of a section view of suchexoskeleton at the midpoint between the front and the rear end of suchstructure.

FIG. 2 is a table listing the base robotic capabilities and baseautomated operations employed by one or more robots in carrying out thesystem and method in accordance with the principles of this disclosure.

FIG. 3 , including sub-parts 3(a) through 3(c), depicts aspects ofassembling such exoskeleton using the bottom-up constructionalternative; and in subpart 3(a) depicts the partially completedexoskeleton with a horizontal cable temporarily attached to a segment ofthe structure being assembled by one or more robots.

FIG. 3(b) provides an example of how the post to which such horizontalcable is attached may in turn be anchored in a hub of the exoskeleton;and subpart 3(c) illustrates connecting the cable to a post, and in turnproviding a guide rail for one or more of said robots to utilize.

FIG. 4 , including sub-parts 4(a) through 4(c), depicts in subpart 4(a)use of inflatable gas bags to hold three-dimensional space until thefull exoskeleton circumference is completed, and in an optionalembodiment to assure that the net weight of the partially completedairship is continuously maintained within a pre-determined acceptableweight range.

FIG. 4(b) shows a section view of a partially completed exoskeletonstructure, inflatable gas bags, and use of a guide wire that may bestrung over said three-dimensional space to enable placement ofhorizontal and vertical guide cables for movement of said robots.

FIG. 4(c) illustrates a single representative gas bag and showscontained therein an optional ballonet for adjusting the buoyancy of thegas bag, as well as the optional use of a woven fabric to reduce therisk of abrasion and/or damage to the gas bags.

FIG. 4(d) illustrates coupling an endcap to each end of the exoskeletonand in turn connecting each endcap to the axle of a turning device inone optional embodiment.

FIG. 5 , including sub-parts 5(a) through 5(c), depict aspects of thetop-down construction alternative. FIG. 5(a) schematically illustrates alayout of floor rails or tracks for use by a class of heavy-lifterrobots that are used in one embodiment to hold the partially completedexoskeleton an appropriate distance from the assembly facility floor andthen to lift the partially completed structure as assembly of theairship frame progresses.

FIG. 5(b) schematically illustrates the use of such heavy lifter robotsto hold a structural frame while construction takes place, and FIG. 5(c)provides a series of the same view over time to illustrate theprogression of such robots lifting, as assembly progresses, theexoskeleton in accordance with the top-down construction alternativeembodiment.

FIG. 6 , including sub-parts 6(a) and 6(b), depicts in subpart 6(a) aperspective view of a heavy-lifter robot holding a partially completedsection of a principal transverse frame while lifting the next modularsegment of frame into place with the assistance of an autonomousassembly robot.

FIG. 6(b) illustrates additional classes of support robots, including aschematic illustration of a swarm of autonomous assembly and fixturingrobots connecting sub-assemblies produced by other robot work cells inconjunction with the assistance of specialized autonomous robots forshuttling raw materials and sub-assemblies to the main assembly area.

While implementations are described herein by way of example, thoseskilled in the art will recognize that the implementations are notlimited to the examples or drawings described. The drawings and detaileddescription thereto are not intended to limit implementations to theform disclosed but, on the contrary, the intention is to cover allmodifications, equivalents and alternatives falling within the spiritand scope as defined by the appended claims. As used throughout thisapplication, the word “may” is used in a permissive sense (i.e., meaninghaving the potential to) rather than the mandatory sense (i.e., meaningmust). Similarly, the words “include,” “including,” and “includes” meanincluding, but not limited to. Additionally, as used herein, the verbs“connect”, “couple” and “attach”, and the corresponding descriptiveterms “connected”, “coupled” or “attached”, respectively may refer tothe act of connecting two or more components together, or the attributeof such components being connected together, whether that connection ispermanent (e.g., welded, glued, bonded, or brazed) or temporary (e.g.,bolted, held by a pin, held in place by friction or tension, or throughjoints or pairing), direct or indirect (i.e., through an intermediary),mechanical, chemical, optical or electrical.

DETAILED DESCRIPTION OF THE DRAWINGS

The subject technology describes improvements over the prior art forassembling airships and other large structures, particularly in aviationand aerospace. In an illustrative embodiment, these improvements areachieved through using specially programmed, autonomous, semi-autonomousand/or human-directed robots to assemble the structural frame, attach,lay-up, or print the skin, and perform other tasks in manufacturing anairship and constructing other structures that are otherwisechallenging, inefficient, or unsuitable for humans to perform, and/orthat would otherwise require significant investments and long-lead timesto build highly capital intensive manufacturing facilities.

These and other aspects of the subject technology are disclosed throughuse of the following illustrative figures.

FIG. 1 , comprised of FIGS. 1(a) through 1(c), illustrates exoskeleton101 in one embodiment of an airship. As shown, FIG. 1 generallycorresponds to the exoskeleton in one preferred embodiment of theairship disclosed in Applicant's prior '145 patent and as moreparticularly described with respect to FIG. 5 thereof. Exoskeleton 101is herein presented as a non-limiting illustration of the frame of anyairship and other large structure whose size and/or weight tends tocause construction using traditional systems and methods to bedifficult, inefficient, or ill-suited for humans to perform, and/or thatotherwise requires significant investments to be made in verycapital-intensive manufacturing facilities and equipment.

FIG. 1(a) shows the full length of airship structure 101, includingfront end 102 and rear end 103, and indicates said airship's approximatemidline 104, and the presence of one or more circular structural frames105 that optionally may be used to provide added rigidity to suchstructure. By way of non-limiting example, a total of 18 circular framesare depicted in the schematic illustration shown in FIG. 1(a), includingcircular frame 105(a) in the front quarter of the airship; 105(b) in therear quarter of the airship; and 105(c), at the midpoint between thefront 102 and rear 103 of the airship structure.

Each such circular frame 105 employs a truss comprised of multiple trussmodules 106 that together make up its full circumference. FIG. 1(b)shows an illustrative example of one such truss module 106 that is builtwith an open, skeletal assembly of longitudinal members 107, struts 108,and joints 109 to achieve a support structure of high load-bearingcapacity relative to its weight. Each truss module 106 includes couplingjoints 110(a), 110(b) and 110(c) that connect with correspondingcoupling joints 111(a), 111(b) and 111(c) of the next adjacent trussmodule. Structural frames 105 are illustrated as being based on thegeometric triangle to take advantage of its inherent rigidity insupporting a coplanar load. Notwithstanding, this shape, as well as thenumber of such structural frames 105, the number of modules 106comprising each such circular frame, and the respective dimensions,weights, construction materials, and methods used to connect theindividual components comprising such modules, are non-limiting, usedfor illustrative purposes only, and may differ without departing fromthe principles of this disclosure.

Also for the purposes of illustration and not limitation, the diameterof airship structure 101 at midline 104 is assumed to be 200 feet, andthe length of the airship is assumed to be 1,000 feet. Such dimensionsrequire an assembly facility whose width and ceiling height is a minimumof 225 feet—roughly equal to the height of a 20-story building; and aminimum length of 1,100 feet—approximately the length of three footballfields placed end to end. Using traditional construction techniques,this roughly 250,000 square foot, twenty-story tall structure, and wouldrequire one or more massive overhead cranes with a free span of at least200 feet that can lift the full exoskeleton or major portions thereof.In the illustrative case, an airship this size is estimated to weighmore than 100 tons, including its structure and skin, and over 200 tonsonce the cockpit, engines, tail, and internal mechanical, electrical,propulsion, thermal management, and storage systems are included.

FIG. 1(c) provides a cross-sectional view of Section A-A from FIG. 1(a).As shown, FIGS. 1(a) and 1(c) include structural members 112, whichoptionally may reflect different intensity levels of framing inaccordance with the selected design of the project sponsor. For thepurposes of illustration only, the structural elements shown in FIG. 1generally correspond to the triangular pattern disclosed with respect tothe exoskeleton in one preferred embodiment of the airship inApplicant's prior '145 patent. As more particularly described therein,there are 48 triangles on each side of midline 104 comprising thecircumference of the structure. The number of triangles may remain thesame, but the length of each structural member will become progressivelyshorter, and the angle of placement will change as the diameter ofexoskeleton 101 becomes narrower. Although as described in greaterdetail within the '145 patent, the number of triangles may drop asconstruction moves in the direction of the front 102 or rear 103,exoskeleton 101 assumes that the number of triangles will remain thesame even as the diameter of the exoskeleton becomes narrower. It willbe apparent to those of ordinary skill in the art that the length,placement, and orientation of such assembly requires precise placementwithin three-dimensional space and appropriate inspection and controlsto assure that the proper parts are used in the proper locations.

One or more autonomous, semi-autonomous, and/or human-directed robots,acting independently and in robot swarms, are used as hereinafterdescribed to address these challenges and overcome other limitations ofthe prior art. In this regard, the '856 patent describes a system andmethod utilizing computer-integrated manufacturing (CIM), amanufacturing approach of using computers to control the entireproduction process. As disclosed therein, which disclosure isincorporated herein in full by this reference, CIM enables flexibleproduct manufacturing using a software-defined product design flow inwhich core robotic capabilities and automated operations are selected,sequenced, verified, tested, and planned; and in which immediatefeedback is provided to designers so they can know if their designs aresuitable for production and/or the robots require additionalcapabilities to be added to the sequence to manufacture such designs.This approach of using computers to control the entire productionprocess, is used in the system and method of the '856 patent to controlindividual processes and enable processing robots to exchangeinformation with each other, and with design personnel, and to initiateactions that can change the way products are produced. This in turnreduces manufacturing time and results in less errors. The system andmethod of the '856 patent also describes utilizing software andcomputerized systems to assist in configuring the manufacture of variousprocess steps, which in turn shortens the time required for factoryreadiness for product production, improves process efficiency, lowersproduction costs, and improves factory efficiency.

Turning to FIG. 2 , table 201 provides a non-limiting list of the baserobotic capabilities 202 and base automated operations 203 that, in onepreferred embodiment, are employed by the one or more robots in carryingout the disclosed system and method. Base robotic capabilities 202 arethe functional elements that can be part of many different tasks; andbase automated operations 203 are the core tasks that the robots aredesigned and programmed to perform through employing these basiccapabilities. It will be understood by persons of ordinary skill in theart of robotics that such core tasks may be performed using differenttooling or end effectors to carry out assigned tasks. For example, thesimplest robots consist of an arm with a tool attached for performing aparticular task; and a different end effector may be attached thatenables the same robot to perform another task. Similarly, persons ofordinary skill will understand that the robotic actions may differdepending on the manufacturing requirements for a particular structure,and further that additional base robotic capabilities 202 and baseautomated operations 203 may be added in combination with alternativetooling and software programming to carry out the spirit and scope ofthe disclosure

To function, a robot must have power; and as shown, the base roboticcapabilities 202 that are necessary for manufacturing variouscomponents, assembling the frame, attaching skin to airship structure101, and performing other manufacturing tasks, include power supply 204.In a preferred embodiment the robots used get their energy fromelectricity. While stationary robots may be used for extrusion andfabrication of parts to be employed in the assembly of airship structure101, and can be plugged in, a significant number of the robots employedwill be required to move around. Such robots require battery power, andin one preferred embodiment utilize hydrogen fuel cell based electricpower to benefit from longer operating duration and greater torquestrength deriving therefrom.

A second vital capability is the robot's control system 205, whichconsists of a central processing unit, or CPU, that can be programmed toperform automated tasks, or to interpret and respond to signals fromsensors 206 to adjust its actions accordingly. In one illustrativeenvironment, control system 205 includes both remote processing andcentralized processing that will enable the robots to functionautonomously, when required, as well as in coordinated actions withother robots or in response to commands provided by human operators,controlling one or more robot actions remotely. In one preferredembodiment, sensors 206 are smart sensors, which collect a specific typeof data from a physical environment (outside or inside) and usecomputing resources that are built into the sensor to perform apredefined and programmed function on the data it is collecting and thenpass that data on via a networked connection. These include, but are notlimited to precise locational sensors, level sensors, pressure sensors,weight sensors, temperature sensors, proximity sensors, heat and flowsensors, fluid velocity sensors, and electric current sensors. Sensors206 monitor different processes, collecting data, taking measurements,and in a preferred embodiment sending this data using the industrialInternet of Things (IIoT) and cloud computing platform to monitor andrecord data from, and in turn to direct and control, the entiremanufacturing process.

Another base robotic capability is movement 207, which encompasses thefull range of mobility and action, depending on the requirements of thetask to be performed. For example, many of the robots used in thedisclosed system and method may be equipped with wheels, threads ormechanism for base automated operations such as rolling 216 on flatsurfaces, irregular surfaces, or along guides or cables, or employ armsthat mimic human movement for climbing 217. Other movements required inmanufacturing the airship including gripping 218, reaching 219, andbraking 220, as more particularly described with respect to FIG. 3 andFIG. 4 , and gripping 218, lifting 226, holding in place 227, connecting227, and inspecting 233 with respect to FIG. 6 , in each case usingactuators that are well known to persons of ordinary skill in the art ofrobotics. To effectively perform these movements, another base roboticcapability in one preferred embodiment is locational awareness 208,which may incorporate data from sensors 206 that detect the robot'scurrent physical location with respect to specified three-dimensionalspatial coordinates, a particular work area or application, or inrelation to one or more other robots; and then can manipulate this datato control actions, information, and the robot's movement.

Locational awareness 208 may also be based on machine vision 209, whichis yet another base robotic capability in one preferred embodiment.Machine vision 209 employs one or more video cameras and/or digitalsensors inside one or more industrial cameras with specialized optics toperform a variety of functions in addition to optionally assisting withlocational awareness 208. In carrying out the system and method, thisincludes identifying 221, for example, specific parts, including but notlimited to by reading a unique identification code printed or otherwisedisplayed on such part and picking 222, for example, the correct partfor carrying out the desired task. Another application of machine vision209 may be to read AprilTags, other visual fiducial markers, and laserpointers to assure the appropriate placement and orientation ofcomponents.

Another base robotic capability is articulated arm 210, which assists incarrying out numerous tasks including but not limited to climbing 217,reaching 219, picking 222, handing 223, placing 224, inserting 225,lifting 226, connecting 229, and attaching 230, as more particularlydescribed with respect to FIGS. 3, 4, and 6 , below. Yet another baserobotic capability is communication 211. It is generally understood thatdistributed intelligence in robotics and autonomous systems applicationsrelies heavily on seamless wireless connectivity. In particular, theIIoT/cloud-based robotics paradigm requires such communicationtechnologies for offloading high complexity computational tasks to theedge/cloud platform. Accordingly, such communication 211 capabilitiesconnect in a preferred embodiment with the central controller system,other robots and, in cases where oversight or remote control by a humanoperator is necessary or desired, with such individuals.

In one optional embodiment, base robotic capabilities 202 also includes3D printing 212, which is an additive process wherein layers of materialare built up to create a 3D part or printed surface area, whichoptionally may be employed in conjunction with articulated arm 210. Onenon-limiting example of where this may be employed is to print the skinor certain portions of the external structure 101, and thereby toachieve functional capabilities that are otherwise difficult orimpossible without employing additive manufacturing technology. Such 3Dprinting 212 may use several different materials, including withoutlimitation, plastics, composites, or metals, to create objects thatrange in shape, size, rigidity, density, and color. 3D printing 212 mayalso be used to produce parts like grippers, sensor mounts, end-of-armtooling, and various replacement parts for other robots employed in thesystem and method.

Changing such end effectors, tooling, robot peripherals, and robotaccessories is important to the smooth operations of the system andmethod. Accordingly, another base robotic capability in an optionalpreferred embodiment is end of arm tooling 213, or automatic toolchanging, which provides an automated process to change tools and passvarious utilities without human intervention. Such end of arm tooling213, in combination with other base robotic capabilities 202, willenable one or more robots, in a preferred embodiment, to perform tasksincluding gripping 218, cutting 228, connecting 229, attaching 230,smoothing 231, and cementing 232, the utility of which, to persons ofordinary skill in the art, will be readily apparent in carrying out thetasks described with respect to FIGS. 3, 4, and 6 , below.

Assembly techniques 214 refers to a library of standardized assemblyroutines or scripts that employ various base automated operations 203 tobe performed by one or multiple robots, alone or in swarms. In onepreferred embodiment, such assembly techniques 214 are software-basedinstructions; and in another optional embodiment, these instructions areburned directly onto specialized ROM-based chips used by one or morerobots. Such assembly techniques 214 preferably include all aspects ofthe manufacturing process, including in one optional embodiment,instructions for buildout of the underlying production process equipmentitself within a building shell. In one preferred embodiment, suchassembly techniques 214 include instructions for the individual processsteps necessary to produce custom fabricated or extruded components andparts, select and assemble these components to produce airship frame101, and to apply the skin thereto. In another one optional embodiment,such scripts are used for adding electrical and mechanical systems,attaching 230 and connecting 229 third-party produced equipment andvessels, and other related tasks.

Machine learning/AI 215 is another base robotic capability in apreferred embodiment. Persons of ordinary skill in the art willunderstand this involves computer systems that are able to learn andadapt without following explicit instructions. This is accomplished byusing algorithms and statistical models to analyze and draw inferencesfrom patterns in data. Incorporating these capabilities will, in onepreferred embodiment, enable the robots used to become more proficientin carrying out the system and method without being explicitlyprogrammed to do so. This is achieved by using historical data as inputto predict new output values. In an optional preferred embodiment, suchprocessing crosses from machine learning to AI (artificialintelligence), which as used herein, indicates that the robots are ableto execute tasks “smartly”, such as by acting in a coordinated mannerwith other robots to complete a task in an optimal manner, or byallowing humans to communicate with such robots using normal, everydaylanguage to perform tasks.

The final two base automated operations 203, inspecting 233 andphotographing 234, employ a combination of multiple base roboticcapabilities 202, including control system 205, movement 207, machinevision 209, articulated arm 210, and communication 211 to provide, inone preferred embodiment, documentation and assurance that the frameassembly and skin surface meet the stringent requirements ofaeronautical certification and performance even though most of thesurfaces being inspected or photographed are well out of the reach ofdirect human inspection.

As noted above, additional base robotic capabilities 202 and/or baseautomated operations 203 may be necessary or desirable to fulfill themanufacturing requirements of a particular oversized or exceedinglyheavy structure. Buttons 235(a) and 235(b) respectively indicate that ina preferred embodiment, there is an ability to add such additionalcapabilities and operating functions where useful to overcoming design,manufacturing, assembly, or inspection challenges; resolving productioninefficiencies; reducing costs or production time; performing tasks thatare unsuitable or unsafe for humans to perform; or increasing quality,reproducibility, and scalability.

Turning next to FIG. 3 and FIG. 4 , a series of illustrations andcorresponding disclosures are provided with respect to using theserobotic capabilities to assemble an airship in a bottom-up embodiment.Following this, in FIG. 5 and FIG. 6 , a series of illustrations andassociated disclosures are provided with respect to an alternativeapproach in which such airship assembly proceeds in accordance with atop-down alternative embodiment. Persons of ordinary skill in the artwill readily appreciate that a hybrid approach incorporating aspects ofboth the bottom-up and top-down assembly alternatives may also be usefuland in many instances represents a preferred embodiment for practicingthe disclosure.

FIG. 3(a) depicts the partially assembled lower portion of exoskeleton101 seated on sled 301 that in one embodiment may be coupled to thestructure in four locations where structure 101 is reinforced forattachment of the interior loading bay area when the airship iscomplete. Sled 301 is preferably made from reinforced carbon fibermembers that are hollow such that they are simultaneously light inweight, very strong, and non-corrosive; and is seated in landing base302 that is specially designed to couple to sled 301 for convenientlyservicing the airship when docked, including in one optional embodimentadding or removing hydrogen to or from said airship; and in anotheroptional embodiment, filling the hollow portion of sled 301 with wateras temporary ballast when unloading cargo and then vacating that waterwhen the airship is about to depart. Landing base 302 is in turnpermanently built on a reinforced foundation 303. In one optionalpreferred embodiment, when the airship is completed, it may be flown toits remote intended base of operations with sled 301 attached, and whereanother landing base 302 has been built for it.

FIG. 3(a) also shows cable 304, which is suspended horizontally betweenposts 305(a) and 305(b). In turn, FIG. 3(b) illustrates how a post 305may be securely coupled with a hub 307 of exoskeleton 101. Hub 307,spokes 308, which attach thereto, and other components thereof arediscussed in detail in the specification of Applicant's prior 145patent, and in particular the detailed description associated with FIG.4 thereof. As shown in FIG. 3(b), opening 306 provides a socket openingfor securely anchoring post 305. Collar 309 serves to restrict post 305from being pushed all the way through opening 306 and in one preferredembodiment, the complementary shapes of post 305 and opening 306 permita secure coupling that will not allow post 305 to turn once embedded inopening 306. Once in place, post 305 may be used either as a base for arobot, and/or cable 304 may be threaded through eyelets 310 to assist intheir movement.

In this regard, FIG. 3(c) provides a cross-sectional view of Section A-Aof FIG. 3(b). As shown therein, cable 304 has been threaded througheyelets 310, and clamp 311 has been applied to assure that cable 304will not slip out. Once such cable 304 is secured at the other end,robot base 312 and wheels 313 can attach thereto, in this way enabling aclimbing robot to move across large spans of open area duringconstruction of exoskeleton 101 and to assist in attaching skin to saidexoskeleton. Once the specific manufacturing process is complete, post305 can be removed from opening 306 and used elsewhere untilconstruction is completed. Clamp 312 illustrates the use of one or moreadditional clamps to optionally restrict the movement of said robot'srange of movement along horizontal cable 304, or to connect a horizontalcable 304 to a vertical cable 403, as more particularly described below.

Through multi-arm robots, including but not limited to spider-bots,employing the base robotic capabilities 202 to perform base automatedoperations 203 in conjunction with the components described within FIG.3 , it will be apparent to persons of ordinary skill in the art howindividual robots, or groups of robots working in a coordinated manner,can work at heights of 50 feet or greater, thereby enabling workers toavoid dangerous conditions when performing assembly and othermanufacturing operations involving an airship or other large and/orheavy structures.

In one embodiment, portions of the exoskeleton may be constructed layingon its side until the full circumference is completed, whereupon thesection is then raised to an upright position so that it can beconnected to other partially completed sections to create a stable basefor attaching guide rails and cables in the manner described. Inanother, embodiment, airship structure 101 can be assembled in a linearfashion, with one or more robots attaching 230 themselves to posts 305in the manner described above to derive support from the one or morerows of assembled hubs 307 and spokes 308 that have already beencompleted. In an optional alternative embodiment, robots insert one ormultiple posts 305 in space 306 of hubs 307 on either side of an openarea generally as illustrated by posts 305(a) and 305(b), install cable304 between them, and then move using wheels 313 along cable 304 tobuild out the open area in between.

In yet another embodiment, cable 304 may be connected at one or bothends to one or multiple secure points that are separate from theairship's own structure 101, for example that are attached to thebuilding or the shop floor in which such assembly is taking place. Inthis case, materials handling robots may move along these cables, withsuch fetching robots identifying 221 the appropriate parts needed at theintended location of assembly on said exoskeleton 101, and then picking222, gripping 218, and bringing (e.g., handling 223) these parts toother robots at or near the intended assembly location. Upon receivingsuch parts from these fetch robots, assembly robots may connect theseparts with others in accordance with assembly techniques 214 thatcorrespond to the design of the frame. By way of a non-limiting example,such assembly technique 214 for the hub and spoke structure described inApplicant's prior '145 patent would entail inserting 225 the two-prongedprotrusion at one end of each insert 314 into one of the six,three-pronged sockets 315 to create a hinged connection on the desiredside of hub 307 for addition of the next spoke 308. That robot, oranother one working in communication 211 with it, would then be able tocouple spoke 308 with the corresponding insert 314, and using locationawareness 208 to cause these structural members to be properly alignedand seated when the structure assembly is completed. One of these robots(or a third one working in communication 211 with them) may then securethe connection by inserting 225 pins 316.

FIG. 4 , consisting of four sub-parts, illustrates other aspects of thebottom-up alternative embodiment. FIG. 4(a) illustrates the use of oneor more inflatable shapes such as gas bags or cells inside the partiallycompleted exoskeleton 101 of FIG. 3(a). As illustrated, in onenon-limiting example, twelve (total) such gas cells are provided, six oneach side of the midline running lengthwise from the front 102 to therear 103 of said exoskeleton 101. In one preferred embodiment, thevolume of all such gas cells is equal, which will result in the shapeshaving different lengths and profiles as the diameter of the airshiphull shape changes. Thus, as illustrated, gas cells 401(a), located onthe left side of this midline, and 401(b) on the right side thereof,have matching shapes that taper down with the final shape of the[future] hull and are quite long; whereas gas cells 402(a) and 402(b) oneither side of said midline directly behind cells 401(a) and 401(b),contain the same volume of gas, but are much shorter in length. Othershapes and configurations of these gas cells may be employed whileadhering to the principles of this disclosure.

In one optional embodiment, such gas cells may contain ambient air andfunction as temporary shapes around which exoskeleton structure 101 maybe constructed. In such optional embodiment, the primary function ofsuch gas cells is to occupy three-dimensional space in the shape of thefuture airship hull, provide resistance that will assist in stability ofthe partially complete exoskeleton 101, and help prevent the structurefrom “falling in on itself” prior to when the stability of the fullcircumference will enable said exoskeleton 101 to maintain its own form.Once inflated, these gas cells will enable vertical cables 403 to bedrawn over the outside surface of such inflatable shapes and connectedto posts 305 inserted in hubs 307 located on either side thereof. Asshown, vertical cables are attached to posts 305(a) and 305(b) in themanner previously disclosed and clamps 314, illustrated in FIG. 3(c),enable horizontal cables 304 to be attached to such vertical cables 403,thereby increasing the areas that can be reached by assembly robots.

FIG. 4(b) shows a section view of the front end of the partiallycompleted exoskeleton structure 101 with inflatable gas cells 401(a) and401(b) located inside, and immediately behind them gas cells 402(a) and402(b). The figure also shows post 305(a) which is used to anchorvertical cable 403 on the right side of the partially completedexoskeleton 101, strung over the top of inflatable gas cells 402(a) and402(b), and then connecting to post 305(c) on the left side of saidexoskeleton frame 101. This will minimize the need for overhead cranesor construction of intermediate crosswalks to hold the partially builtexoskeleton until the full circumference of exoskeleton 101 can becompleted, thereby enabling the structure to distribute the weight ofthe airship along the full circumference thereof.

Turning to FIG. 4(c), an illustration is provided of gas cell 401(b), asrepresentative of all the gas cells. As shown therein, in one alternateembodiment, the inflatable shapes may be filled with a lifting gas suchas helium or hydrogen, and optionally may include a second, inner gascell 404 that is filled with air. Persons of ordinary skill in the artof lighter-than-air design will recognize the similarity of inner gascell 404 to a so called “ballonet”, which is generally understood to bean air bag that is located on the inside of the outer envelopecontaining the lifting gas such that, when the ballonet is inflated, thevolume available for the lifting gas is reduced, thereby increasing itsdensity, reducing the overall lift and in turn causing the descent ofthe airship, while deflating the ballonet increases lift. Whereasballonets are typically used for buoyancy control in non-rigid orsemi-rigid airships—and in fact may, or may not, have any utility tooperation of the airship being constructed depending on the designintentions of its sponsor—the use of an inner gas cell 404 within eachinflatable shape may be useful in the manufacturing of such airship.

In yet another alternate embodiment, gas cell 401(b) and the remaininggas cells may be filled with air, and inner gas cells 404 may be filledwith the desired lifting gas (e.g., helium or hydrogen). Thisalternative embodiment has the advantage of being closer to theconfiguration of gas bags used in rigid airships, wherein the liftinggas cells are flexible envelopes protected within the airship hull. Insuch case, each lifting gas cell has an access point for filling (e.g.,adding the lifting gas) and venting it if necessary; and around the gascells is an envelope of air that serves as a safety feature. To theextent that hydrogen is used as the lifting gas, as hydrogen moleculesslowly migrate through the wall of the gas cells, this leakage needs tobe dissipated prior to reaching a flammable concentration. Sincehydrogen rises rapidly the airship is constructed with a slow, butsteady flow of air along the top of the gas cells, along with monitorsto measure the hydrogen concentration, and the ability to increase theventilation if needed.

In another embodiment, an outer layer of lightweight fabric 405 such asaramid fiber or Kevlar® is produced in the desired form of the inflatedshapes and placed around their outside surface to reduce the risk ofabrasion should they inadvertently come into contact with theexoskeleton as well as to reduce the risk of such shapes being damagedduring construction. In one preferred embodiment, “sleeves” may bedesigned in the lightweight fabric through which spokes 308 can bethreaded during assembly of the exoskeleton. Doing this will assure thatsaid shapes adhere to the desired portion of the exoskeleton structure101. In some optional embodiments, the inflatable shapes and this fabricmay be removed upon completion of construction, and in other preferredembodiments, the one or more inflatable shapes and this fabric willremain permanently inside the exoskeleton for the lifetime of theairship, and be used in its operation following completion ofconstruction. In a preferred embodiment, helium may be used as thelifting gas during construction and hydrogen may be used once theairship is complete and placed into operation.

And in some embodiments, the placement of hubs, spokes and other keycomponents may be drawn directly using human and/or machine-readabletext or tags onto the surface of the one or more inflatable shapes, orthe lightweight fabric 405 to assist the robots in identifying 221 andplacing 224 such components in three-dimensional space. In otheroptional embodiments, the robots or robot “swarm” may utilize suchdrawings and optional unique numbers and tags to ensure that the rightcomponent part is assembled in the correct position for the finishedexoskeleton and skin placement to be in accordance with the intendeddesign therefor.

Using one of the foregoing gas cell alternatives, in one embodiment thebuoyancy of such inflatable shapes may be adjusted to maintain a neutralor desired level of negative buoyancy of the airship or selected portionthereof. This will ensure that the weight of such airship or portionthereof always remains in a predetermined acceptable range asconstruction proceeds, and will minimize the need for cranes, mechanicaland/or hydraulic jacks, and other lifting equipment. In one preferredembodiment, an automated control system may be programmed to control therelative quantities of lifting gas and air that is contained in the oneor more inflatable shapes, the objective of such control systemprogramming being to continuously monitor the net weight of thepartially completed airship and to maintain the desired buoyancycharacteristics by adjusting the quantities of air and lifting gas asconstruction progresses so as to maintain both the integrity of said oneor more inflatable shapes as well as the overall neutral or desired netnegative buoyancy level at all times.

In one embodiment, the effective net weight of the airship (e.g., thetotal weight of the parts of the ship that has been completed less theeffect of the lifting capacity of the lifting gas-filled inflatableshapes) is maintained in the range of between 10,000 to 20,000 pounds.The range (e.g., 5 to 10 tons) may be changed in accordance with thewishes of the manufacturer and illustrates the principle of this aspectof the disclosure that notwithstanding that the actual combined weightof the airship may eventually reach in excess of 250,000 pounds, theeffective weight can, be kept much more manageable by practicing thedisclosed principles.

In one embodiment, prefabricated curvilinear parts comprising portionsof the skin are attached 230 to the exoskeleton through robots carryingout their assembly techniques 214. In another, the skin is applied,layed-up, or cemented 232, smoothed 231 and inspected 233 to assure itdoes not have wrinkles, bubbles, dimples or other unacceptableimperfections. In an optional embodiment, additive constructiontechnology 212 may be used to provide portions of the exoskeleton and/orskin. In such embodiment, one or multiple robots mount onto posts 305,horizontal cable 304 and/or vertical cable 403 and, using one or morecomputer-controlled articulating arm(s) 210, lay-up or 3D print 212these components. Optionally, in such cases, a second robot or robotswarm later smooths 231 the surface in order to minimize skin frictionand drag during flight.

FIG. 4(d) illustrates another one alternative embodiment. In someembodiments, once the exoskeleton 101 is completed, a temporary endcap406(a) is coupled with the front 102 of said exoskeleton 101, andtemporary endcap 406(b) is coupled with the rear 103 thereof. The axle407 of a turning device 408 may be temporarily coupled thereto. Gettingthe completed airship on this device his process may be assisted byadjusting the height of the turning device on its mounting 409 andsimultaneously reducing the effective net weight of the airship usingthe previously described automated control system to increase therelative quantity of lifting gas and reducing the volume of air that iscontained in the one or more inflatable shapes. Once coupled to suchturning machine 408, in one preferred embodiment, the amount of liftinggas may then be adjusted to further reduce the effective net weight ofthe airship to approximate neutral buoyancy, whereupon in one embodimentthe full airship body may be turned by said turning device 408 to assistin inspections, laying-up a smooth skin surface, and other desiredproduction steps.

And in other optional embodiments, selected ones of the inflatableshapes may used to cause the front of the airship 102 to be lowered andthe rear of the airship 103 to be elevated to assist in coupling endcap406(a) or the front compartment that attaches to said exoskeleton. Inanother optional embodiment, selected ones of the inflatable shapes maybe used to cause the rear of the airship 103 to be lowered, and thefront 102 elevated, to assist in coupling endcap 406(b) or mounting orworking on the aft engine.

Turning next to FIG. 5 , several illustrations are provided with respectto an alternative approach in which the airship assembly proceeds inaccordance with the top-down alternative embodiment. FIG. 5(a)illustrates a view of the manufacturing facility floor 501 on whichdashed line 502 represents an imaginary shape of the outer edge of thecompleted surface of airship 101 (referred to herein as its drip line).The vertical lines shown extending just beyond the edge of said dripline 502 illustrate epoxy or stud-mounted subplate tracks 503 that areattached to the facility floor, the placement of each such trackcorresponding to the location of a circular support frame 105 in airship101. As illustrated, track 503(a) corresponds to the location of supportframe 105(a) in the front quarter of airship 101 as one looks in thedirection of arrow 504(a) pointing toward the front of the airship.Track 503(b) corresponds to the location of support frame 105(b) in therear quarter of airship 101 as one looks in the direction of arrow504(b) pointing toward the rear of the airship. Track 503(c) correspondsto the location of support frame 105(c) at the midline 104 of airship101. Each of such tracks 503 provides a linear path for two or moreso-called hand-over-hand (HOH) support robots 505, as more particularlydescribed with respect to FIG. 5(b) and FIG. 6 , below.

FIG. 5(b) illustrates the primary function of such HOH support robots inlifting 226 and holding in place 227 the partially completed airship101, and thereby ideally enabling assembly and construction activity onthe structure, outer surfaces, and interior components to be performedat or near the factory floor 502. The view shown in FIG. 5(b) is SectionA-A along linear track 503(c) from FIG. 5(a) near the beginning ofconstruction. HOH support robots 505(a) and 505(b) respectively hold 227the left and right ends of the top portion of partially completedstructural frame 105(c), which contains six truss modules 106(a) through106(f). As more particularly described with respect to FIG. 6 , below,HOH support robot 505(a) is gripping 218 truss modules 106(a) and106(b), while HOH support robot 505(b) is gripping 218 truss modules106(e) and 106(f). These truss modules are in turn connected to the apexof structural frame 105(c), which is comprised of truss modules 106(c)and 106(d).

FIG. 5(c) shown six arbitrary views of section A-A from FIG. 5(a),beginning with section view 506(a), corresponding to view shown in FIG.5(b). The next five views illustrate the progression of construction ofsupport frame 105(c), from these first upper-most modules beingconnected 229 in section view 506(a), until the airship is completed insection view 506(f). These six illustrative views show the position ofHOH support robots 505(a) and 505(b) along linear track 503(c) given thelevel of completion of airship 101 at the time; and the addition of twocorresponding HOH support robots for each circular structural frame thatis added as progression of the construction proceeds in the direction ofarrow 504(b) in FIG. 5(a) from midline 104.

As shown in section views 506(a) and 506(f), respectively, HOH supportrobots 505(a) and 505(b) start and end closest together, near the middleof linear track 503(c). In section views 506(b), 506(c) and 506(d), HOHsupport robots 505(a) and 505(b) move farther apart as airship 101 isconstructed, reaching their maximum separation at the “equator” (e.g.,the halfway point between the top and bottom of the airship) of suchassembly, illustrated in section view 506(d). As detailed in FIG. 6 ,HOH support robots 505 have a pivoting axis that enables the support armto always accord with the curvature of circular frame 105. The rotationof this pivot axis by +/−90 degrees allows HOH support robots 505 toadapt to both concave and convex curvatures with respect to the buildcenterline. Accordingly, once the equator of the structure passes thebuild level, the support robots are rotated horizontally and rolled frominside to outside to complete the build. This is illustrated in sectionviews 506(a)-506(d), showing HOH support robots 505(a) and 505(b)positioned on the inside of circular frame 105 in these earlier stagesof construction, and showing such HOH support robots 505(a) and 505(b)moving to the outside of the build in section views 506(e) and 506(f)once the equator has been passed.

Although construction of airship 101 will begin with circular supportframe 105(c) being assembled from linear track 503(c), as illustrated insection view 506(a) and FIG. 5(b), as the airship's constructionprogresses towards the equator, the assembly will also move in thedirection of the front 102 and rear 103 of the structure. As the activeareas where construction build is taking place moves laterally (e.g., inthe direction of arrows 504(a) and 504(b), respectively), additional HOHsupport robots 505 will be added to each successive linear track, wheresuch robots will function in the same manner as described with respectto those on linear track 503(c). Thus, as illustrated in section views506(d) and 506(e), once construction of airship 101 reaches the equator,two HOH support robots 505 will be in use on each of linear tracks 503.Optionally, some or all of such HOH support robots 505 may remain inplace to provide additional support, where necessary, once each suchcircular support frame 105 is completed, as shown in section view506(f).

Turning next to FIG. 6 , a schematic illustration of such HOH supportrobots 505 is provided in FIG. 6(a). As shown, in a preferredembodiment, linear bearing rails 601 are attached to linear track 503.Although in one embodiment, HOH support robots 505 may not employ trackmounting, in a preferred embodiment these mobile robots are trackmounted because there are possible cases where there will be upwardstresses (for example, during a positive buoyancy stress test) or highmoment loads being transferred to the floor. Although the optional useof gas cells as disclosed with respect to FIG. 3 and FIG. 4 may providesome of this support for more heavy phases of the build, in a preferredembodiment, the HOH support robots 505 employ the conservativeassumption that there is no such off-loading, thereby requiring HOHsupport robots to carry the entire weight of airship 101 by the time itis completely assembled.

Assuming that completed airship 101 weighs a total of 400,000 pounds,and assuming it has 16 structural frames 105, then eight (8) HOH supportrobots 505 will be employed on each side. In this instance, each HOHsupport robot 505 would need to support approximately 25,000 pounds,plus a safety factor to account for heavier weights in some areas andthe possibility of buoyant off-loading. Although various methods ofattachment are possible, the use of linear bearings 602(a) and 602(b)provides high load capacity, rigidity, and shock and impact resistance,while providing support for the load of the robot's carriage 603 duringits movement along linear track 503 and provides a low friction slidingsurface for the bearing rails 601. In an optional embodiment, carriage603 may also be provisioned to extend upward (e.g., in a Y-axisdirection) to support portions of the airship at one or both ends onceconstruction of airship 101 has proceeded beyond the equator andconstruction of the corresponding circular support frame 105 for thatportion of airship 101 is completed.

Persons of ordinary skill in the art will recognize that several methodscan be used to drive robot's linear (e.g., X-axis) motion, including butnot limited to belts, rack and pinion, and chain drives. As illustrated,in a preferred embodiment, HOH support robots 505 use rack 604 andtraverse drive (pinion) 605. To reduce cabling, the power supply 204 forHOH support robots 505 will in a preferred embodiment employ on boardbatteries. Because these robots move only short distances at a time andsit idle during most of the assembly period, in a preferred embodiment atrickle charge may be provided through the linear bearings for toppingoff the on-board batteries.

As described with respect to FIG. 5(b), HOH support robots 505 are heavylift devices with a pivoting axis 606 to allow the robot's arm assembly607 to rotate +/−90 degrees so that it is oriented in accordance withthe build centerline 608 for its respective circular structure frame 105and thereby to accommodate both concave and convex curvatures as theairship build progresses. In a preferred embodiment, such pivoting armassembly 607 provides gripping 218, lifting 226, and holding in place227 functions. Assuming the use of triangular shaped trusses toconstruct circular structure frames 105, in a preferred embodiment, sucharm assembly 607 contains a total of nine node grippers 609 mounted insets of three node grippers each, on recirculating tracks 610 with drivemeans.

Node grippers 609(a), 609(b) and 609(c) are shown as connected torecirculating track 610(a); node grippers 609(d), 609(e) and 609(f) areconnected to recirculating track 610(b) (with node gripper 609(d) beinghidden behind other portions of the illustration); and node grippers609(g), 609(h) and 609(i) are connected to recirculating track 610(c).Arrows 611(a) and 611(b) indicate the direction that recirculating track610(a) moves when HOH support robot 505 lifts the truss modules 106 itis gripping (as hereinafter described) and in turn lifts the structuralframe 105 these modules comprise; and arrows 611(c) and 611(d)respectively show the return of recirculating tracks 610(b) and 610(c)and their corresponding node grippers 609.

Three truss modules 106 are shown in various stages of assembly intotheir corresponding structural frame 105. As illustrated, truss module612(a) is being moved into position by assembly and fixturing robot(FixBot) 613, the features of which are described below. As shown,FixBot 613 is positioning coupling joints 110(a), 110(b) and 110(c) oftruss module 612(a) into, respectively, gripping node 609(i) onrecirculating track 610(c), gripper node 609(f) on recirculating track610(b), and gripper node 609(c) on recirculating track 610(a). Onceproperly positioned, in a preferred embodiment FixBot 613 (or a secondFixBot with the appropriate end of arm tooling 213 for attaching thesecoupling joints in the desired manner) connects the corresponding threecoupling joints 111(a), 111(b) and 111(c) of truss module 612(a) tocoupling joints 110(a), 110(b) and 110(c) of truss module 612(b).Gripper nodes 609(h), 609(e), and 609(b) then grip onto the connectedjoint between truss modules 612(a) and 612(b), thereby holding thesemodules firmly in place 227 while work proceeds on the layercorresponding to truss module 612(c), including connecting the rest ofthe structural elements and skin as described with respect to FIG. 6(b),and connecting other components of airship 101 for that layer ofassembly.

When all components of the layer have been completed, gripping nodes609(a), 609(d) and 609(g) will open, thereby releasing the last hold ontruss module 612(c), and recirculating tracks 610(a), 610(b) and 610(c)will lift truss modules 612(a) and 612(b), thereby indexing upward thecorresponding structural frame 105 comprised of truss modules 610(a),610(b) and 610(c), the corresponding three truss modules 106 on theopposite side of airship 101, and all of the truss modules 106connecting between them. A similar action will simultaneously beperformed by HOH support robot 505 pairs holding any other circularframes 105, thereby raising the entire structure 101. Once this iscomplete, the foregoing sequence of steps will be repeated untilconstruction of the entire structural frame, attachment of its skin, andconnection of associated components is completed.

It will be apparent to persons of ordinary skill in the art that theactions of any HOH support robots 505 in contact with the airship 101structure must be coordinated to ensure that such structure 101 will beraised in the desired manner. HOH support robots 505 will have identicalstop and start times, but different rates. To ensure proper action, allHOH support robots 505 will be finely coordinated by the system'scontrol systems 205, pre-programmed assembly techniques 214, andcommunications 211, with the failure of any recirculating track 610,gripper node 609, traverse drive 605 or pivot drive 606 to function inthe expected manner resulting in immediately halting the actions of allHOH support robots 505 until such fault has been diagnosed andcorrected.

As indicated above, FixBots 613 are a light payload robot that isprogrammed to hold sub-assemblies such as truss modules 106 in place.Each an autonoumous guided vehicle (AGV), such FixBots 613 are also usedthroughout the manufacturing facility for other materials handling andplacement duties. To enable FixBots 613 to travel autonomously withoutan onboard operator or driver, they are constructed on an autonomousmobile robot (AMR) base 614 such as those manufactured by Bosch Rexroth.And to perform a broad range of tasks, each such FixBot 613 has asix-axis articulating arm 615, such as manufactured by FANUC, YaskawaMotoman, ABB, and KUKA, and is equipped with end of arm tooling 213 toperform its tasks and camera 616 to read fiducials of destination andpart-in-grasp in order to position such sub-assemblies accurately aswell as to perform inspections.

Turning next to FIG. 6(b), FixBots 613(a) and 613(b) are shown equippedwith different end of arm tooling that equips them to assemble andconnect the structural elements between circular structural frames 105.By way of a non-limiting example of operating as a robot swarm, FixBot613(a) is shown holding spoke 308 in place while FixBot 613(b) connectsit at a hub 309 to other spokes. The figure also illustrates othersub-assemblies 617 that are connected to truss module 612(c) withconnectors 618, and the attachment of skin 619 onto such exoskeleton.FIG. 6(b) also shows another specialized class of robots, calledFetchBots 620, that may be used in a preferred embodiment to shuttle rawmaterials such as pre-cut lengths of spokes 308 and pre-assembledcomponents such as sub-assemblies 617 to the main assembly floor fromother areas of the facility where these components are produced,inventoried, and otherwise prepared by robot work cells. As shown, suchFetchBots contain an AMR base 614 and specialized truck 621 for holdingsuch raw materials and sub-assemblies.

In a preferred embodiment, all the assembly steps, processes involved inattaching 230 laying up or 3D printing 212 the skin and assuring thefinished surface is appropriately formed and smooth, and other stepsinvolved in manufacturing the airship will be carried out in a similarmanner. As this work is performed, the base robotic capabilities 202 canalso be used to provide automated quality oversight through inspections233 and/or by enabling human supervision of such robotic activitythrough use of machine vision 209 and communication 211 with a remotescreen used by said supervisor from the factory floor, a control room,or observing from a remote location. The combination of experiencedtechnicians overseeing in real time and/or by asynchronously observingphotographs 234 of such robotic activity performed in accordance withthe disclosed system and method will yield superior performance resultsin a fraction of the time, and at a fraction of the cost of traditionalconstruction approaches.

Moreover, based on the foregoing disclosures, it will also be apparentto persons of ordinary skill in the art how the requirements of thefactory infrastructure in which such assembly takes place cansimultaneously be reduced. While a large physical structure is stillrequired for such operations to be shielded from the elements and in aprotected environment, the disclosed system, method and apparatuspermits the project sponsor to avoid the need for very costly elevatedconstruction platforms, one or more huge overhead cranes, and theadditional foundations, heavily reinforced structures, and associatedbuilding infrastructure to support such elements as would otherwise berequired when employing traditional manufacturing techniques.

Using the foregoing disclosures, without needing to perform undueresearch, robotics suppliers such as KUKA, ABB (ASEA Brown Boveri),Omron Adept Technologies, Mitsubishi Electric, Bosch, Yaskawa, Kawasaki,Nachi-Fujikoshi, Comau Robotics, Yamaha, IGM, Rethink Robotics, Arrival,and others can provide robots and control systems 205 able to carry outall the base automated operations 203. Such suppliers will also beenabled to compose assembly techniques 314 from CAD drawings provided bythe airship designers that such robots can use to perform the tasksrequired to assemble exoskeleton 101 and complete other manufacturingsteps in accordance with the principles of this disclosure. It will beapparent to persons of ordinary skill in the art how, by following suchcomputer controlled, pre-programmed assembly techniques 214, and/orutilizing machine learning/AI 215, such robots may be trained to respondto different structural shapes, systems, parts numbering schemas, tags,and markings for each such manufacturing project.

In another preferred embodiment, these robots can utilize machine vision209 and machine learning 215 to adapt to the geometry of the airshipexoskeleton 101, and perform other specialized tasks needed to constructthe airship. In addition to labor savings and safety benefits, and theability to reduce the capital cost of manufacturing facilities and theneed for specialized equipment, the disclosed system and method are alsodesigned with manufacturing speed and scalability in mind. For example,the time required for construction can be accelerated by assigningadditional robots to work in a coordinated fashion on specific tasks, orby employing additional “teams” of robots that are programmed to work inparallel on different parts of the airship, thereby making it possibleto readily scale-up production levels to meet the desired projectduration goals virtually regardless of the size of the airship and thenumber of airships. In addition, by duplicating assembly techniques 214,additional manufacturing facilities can be readily developed in othergeographic areas, thereby making it possible to expand the number ofassembly locations and rapidly enter multiple markets, create goodpaying jobs, and add to local tax revenue—all of which will assist inbuilding broad community support and adoption.

In summary, based on the foregoing disclosures, it will be apparent topersons of ordinary skill in the art how by using bottom up assemblymethods, top down assembly methods, and/or useful combinations of thetwo methods, multiple teams of robot-based work cells producing rawmaterials and sub-assemblies, FetchBots 620, and FixBots 613, can workin tandem with HOH support robots 505, and robots equipped to climb, toconstruct airships in a faster, less costly, higher quality, andsignificantly more replicable and scalable manner than in the prior art,while simultaneously overcoming the stated limitations of such prior artmethods.

From the foregoing disclosure, it will be appreciated that, althoughspecific implementations have been described herein for purposes ofillustration, various modifications may be made without deviating fromthe spirit and scope of the appended claims and the elements recitedtherein. In addition, while certain aspects have been presented asalternative, optional or preferred embodiments, all such embodiments arenot required and thus may be incorporated as dictated by thecircumstances to achieve the desired result. Moreover, while certainaspects are presented below in certain claim forms, the inventorscontemplate the various aspects in any available claim form. Variousmodifications and changes may be made as would be obvious to a personskilled in the art having the benefit of this disclosure. It is intendedto embrace all such modifications and changes, and accordingly, theabove description should be regarded in an illustrative rather thanrestrictive sense.

What is claimed is:
 1. A method of robotically manufacturing an airshipfrom the top down, the method comprising: placing a partial airship hullonto at least one truss held by at least one supporting robot; using oneor more specialized robot worker classes to complete a construction taskcycle on a selected work surface of said partial airship hull assemblythereby completing a construction task cycle on upper sections of theairship; robotically elevating the active assembly work surface of saidpartial airship hull assembly with at least one supporting lift robot;selecting a further lower active assembly work surface and roboticallycompleting a construction task cycle on said further selected lowerassembly work surface; and repeatedly elevating subsequent lower activeassembly work surface and robotically completing a construction taskcycle on subsequent selected lower active assembly work surfaces untilthe airship has been fully constructed.
 2. The method of claim 1 whereinthe at least one supporting robot is capable of adjusting the point ofcontact of the at least one truss with the airship according to theposition and curvature of a frame of the airship.
 3. The method of claim1, wherein the construction task cycle on the airship is performed byone or more robots working independently or within a robotic swarm. 4.The method of claim 3, wherein the robotic swarm comprises at least onesupporting robot in communication with one or more another supportingrobot in order to correctly orient themselves according to theconstruction task in the assembly of the airship.
 5. The method of claim3, wherein the robotic swarm comprises multiple robots that are eitherhomogeneous and heterogeneous or mixtures thereof forming a swarm ofrobots, wherein individual robots within the robotic swarm haveprocessing, communication and sensing capabilities allowing said robotsto interact with each other and to accomplish the construction taskcycle.
 6. The method of claim 1, wherein the robotic swarm comprises atleast one heavy lift robot in conjunction with other specialized robotsto complete the construction task cycle of the airship.
 7. The method ofclaim 1, wherein an outside surface material of the airship hull isapplied by specialized homogeneous robots within the robotic swarm. 8.The method of claim 1, wherein each of the at least one robot comprisingsaid robotic swarm is controlled by pre-programmed routines, artificialintelligence, or a combination thereof.
 9. The method of claim 8 whereinrobots within the robotic swarm utilize remote cameras, computer vision,and machine learning to perform specific and unique functions whencompleting construction task cycles of the frame, exoskeleton, covering,or other portions of the airship.
 10. The method of claim 9, whereineach robot attaches itself to and derives support from one or morecomponents that have already been assembled.
 11. A method of roboticallymanufacturing an airship, the method comprising: attaching a partiallycompleted airship exoskeleton to a sled; inserting at least one postinto at least one hub of the exoskeleton of the airship; attaching atleast one cable to the at least one post; attaching at least one robotto the at least one cable; and utilizing the at least one robot tocomplete construction of the lighter than air airship.
 12. The method ofclaim 11, wherein the at least one robot is in communication with one ormore robots having a homogenous or heterogenous function forming arobotic swarm.
 13. The method of claim 12, wherein the robots within therobotic swarm are configured with sensory systems permitting automatedquality oversight and human supervision from remote locations.
 14. Themethod of claim 13, wherein the robots within the robotic swarm arecontrolled by manual control, wireless control, are semi-autonomous orfully autonomous.
 15. The method of claim 14, wherein the fullyautonomous control uses pre-programmed routines, artificialintelligence, or a combination thereof to control the function and taskof the robotic swarm.
 16. The method of claim 11, furthering comprisingthe step of inserting at least one gas cell within the exoskeleton ofthe airship, wherein said gas cell contains air or a lighter-than-airgas that maintains the shape of the exoskeleton during construction orreduces the weight of the airship needed to be supported.
 17. The methodof claim 11, wherein at least a portion of the airship is constructedwhile laying on a side and subsequently raised into an upright positionby at least one heavy lifting robot, allowing for completion ofconstruction of the airship.
 18. The method of claim 11, wherein the atleast one robot possesses a locomotion mechanism configured to conductself-locomotion or guided locomotion.
 19. The method of claim 11 furthercomprising a gantry to protect the at least one robot from falling. 20.The method of claim 11, wherein portions of the exoskeleton or otherportions of the airship are robotically constructed in separateprocesses and are subsequently combined into another manufacturingprocess.
 21. The method of claim 11 wherein the at least one robot isconfigured to build the exoskeleton, attach exterior skin, or performother tasks associated with manufacturing.
 22. The method of claim 16further comprising: connecting at least one front end cap and at leastone rear end cap to the exoskeleton; fastening at least one front endturning device and at least one rear end turning device to theexoskeleton; adjusting the level of lifting gas within the at least onegas call to reduce the weight of the airship needed to be supported; andemploying the at least one front end turning device and the at least onerear end turning device to rotate the exoskeleton.
 23. A method ofrobotically manufacturing an airship, the method comprising: placingpart of the airship onto at least one truss held by at least onesupporting robot; robotically completing part of a construction task onthe airship; releasing at least one grip node of the at least onesupporting robot and raising the at least one truss by rotating at leastone recirculating track; robotically completing a construction taskcycle on the airship; and repeating construction task cycle until theairship has been fully constructed.
 24. The method of claim 23, whereinan automated control system is configured to control the quantities ofair or a lighter-than-air gas contained in at least one gas cell. 25.The method of claim 23, wherein the at least one supporting robot iscapable of adjusting the point of contact of the at least one truss withthe airship according to the position and curvature of a frame of theairship.
 26. The method of claim 23, wherein the construction task cycleon the airship is performed by one or more robots working independentlyor within a robotic swarm.
 27. The method of claim 26, wherein therobotic swarm comprises at least one supporting robot in communicationwith one or more another supporting robot in order to correctly orientthemselves according to the construction task in the assembly of theairship.
 28. The method of claim 27, wherein the robotic swarm comprisesmultiple robots that are either homogeneous and heterogeneous ormixtures thereof forming a swarm of robots, wherein individual robotswithin the robotic swarm have processing, communication and sensingcapabilities allowing said robots to interact with each other and toaccomplish the construction task cycle.
 29. The method of claim 28,wherein the robotic swarm comprises at least one heavy lift robot inconjunction with other specialized robots to complete the constructiontask cycle of the airship.
 30. The method of claim 28, wherein anoutside surface material of the airship is applied by specializedhomogeneous robots within the robotic swarm.
 31. The method of claim 28,wherein each of the at least one robot comprising said robotic swarm iscontrolled by pre-programmed routines, artificial intelligence, or acombination thereof.
 32. The method of claim 28, wherein robots withinthe robotic swarm utilize remote cameras, computer vision, and machinelearning to perform specific and unique functions when completingconstruction task cycles of the frame, exoskeleton, covering, or otherportions of the airship.